>> F A C T S:

The enterprise founded in Ranshofen/Austria in 1983 as AUSTRIA ALU-GUSS Ges.m.b.H. has been part of the BORBET group since 1983. Since 1st January 2009, the enterprise operates under the name BORBET Austria GmbH.

For decades, the traditional enterprise Borbet has be-en ranking among the leading aluminium wheel manu-facturers worldwide and, supplies a considerable num-ber of important automobile companies.

Manufacturer of Aluminium Wheels Counts on Industry 4.0 –Gain Value-added Information from Data

In order to be able to identify and analyze process disturbances and optimize information flows, Borbet decided to implement the MES software solution Plant Historian.

>> Initial situation: In order to reduce downtimes and achieve improve-ments in the production process, resource and time intensive data analyses and employees surveys were necessary. The lack of availability of relevant produc-tion data represented the cause of a lack of transpar-ency in the production process.

The result was a along and inefficient communication chan-nel within the company, with suppliers and clients. A continuous improvement process was difficult to achieve, optimization potentials were not fully exploit-ed. Systematic research into the causes of downtimes was problematic.

>> Project targets:

Identification of optimization potentials in three-shift operation

Transparent presentation of process data and key figures

Additional information out of the company's ope-rating data system

Digital collection of data out of approx. 65 pro-duction lists

Digital collection of shift event data

Support for the installation of a new paintwork plant

Support for client audits

Fluent and efficient information exchange within the shift personnel and the departments, with auditors and suppliers

>> Implemented modules / functionalities:

Plant Historian AM - Alarm Management

Plant Historian PDA - Process Data Archiving

Plant Historian RM - Reporting Module

Plant Historian SB - Digital Shift Book

Plant Historian LAB - Laboratory Data Acquisition

Manufacturer of Aluminium Wheels Counts on Industry 4.0 –Gain Value-added Information from Data

In order to be able to identify and analyze process disturbances and optimize information flows, Borbet decided to implement the MES software solution Plant Historian.

Plant Historian is applied for:

Long-term archiving of process data and events (events & alarms)

Individual reporting: shift reports are automatically generated and forwarded, KPI reporting of the production

Identification of optimization potentials and cau-ses for failure

Transparency of production processes with the help of individual trend groups, event and labora-tory information

Digital collection of shift events, laboratory data and manual values

>> Former status

A transparent evaluation of process data, alarms and events was not possible, as data were only partly avail-able.

Relevant key figures could be generated, but only man-ually and in a time-consuming way.

Shift events needed long communication channels for transmission, research for quality data was resource and time-consuming. The manual documentation of big data volumes made a reasonable evaluation almost impossible.

Complicated audit preparations meant high resource binding of persons in higher positions.

>> After the implementation of Plant Historian AM:

The use of iMes Solutions Plant Historian has made data available and evaluable. Optimization potential can be identified. Automated reporting generates auto-matic and accurate reports. Production relevant data are available immediately after the end of a shift. Shift reports are forwarded to a predefined selection of re-cipients. Better communication within and outside the company is responsible for a fluent and transparent information flow. Research work has been reduced by 90% since the introduction of Plant Historian. Laborato-ry data and manual values are digitally collected and can be edited ad hoc.

Mr. Dax (head of the paint shop, Borbet project man-

ager for Plant Historian) talks about project manage-

ment and realization: „The excellent cooperation be-

tween Mr. Walter Eberhardt, the Borbet IT depart-

ment and the iMes Solutions team was fundamental

for the project success. Our IT department was re-

sponsible for the fast supply of the IT infrastructure

and, additionally, the connection of the flexible data

of the process data acquisition system (PDA) with

the reporting module of Plant Historian. The resulting

shift reports make daily analysis work so much easi-

er. Above all, the integration of data from our PDA

into the iMes reports reveals optimization potential

on one hand and confirms successful production

processes on the other. All objectives have been

achieved – at the highest level of satisfaction.”

Plant Historian represents an efficient, con-

sistent and transparent MES solution for the

manufacturing

industry. Plant Historian connects shopfloor and

ERP level with the targets of production cost re-

duction, fault avoidance and communication op-

timization.

>> Comments of the Borbet representatives:

Mr. Walter Eberhardt (Borbet electrical engineering / paint shop): „The connection between Plant Historian and the control system was completed within one work-ing day. The applications run without any failure times and, the documented values are directly available. The intuitive operation of the analysis tools results in a fast identification of process disturbances, which makes im-mediate response possible. Shift reports are very helpful for inter-departmental cause research and early initiation of maintenance services.”

Key figures generation at the push of a button replaces time-consuming audit preparations. The high ac-ceptance of the software Plant Historian by the employ-ees underlines its usability. The above mentioned measures have led to a transparent, resource and time-saving production process with a considerable increase not only of the quality, but also of the competitiveness of the enterprise.